Microsoft Word - ZEX109.docZEX™ * 3418 Democrat Rd. * Memphis, TN
Phone: 888-817-1008 * Fax: 901-375-3430
http://www.zex.com
ZEX™ Nitrous Injection System Thank you for choosing ZEX™; we are
proud to be your manufacturer of choice. If at any time you have
questions regarding this or any of our products please call our
toll free product support line at 1-888-817-1008.
Warning: Read these instructions completely before attempting to
install your nitrous oxide injection system. Failure to do so may
result in damage to your engine or vehicle and/or physical harm to
yourself. ZEX™ is not responsible for damage or injuries caused by
improper use of this nitrous kit.
Part # ZEX109 Revised 1/22/04
ZEX™ * 3418 Democrat Rd. * Memphis, TN Phone: 888-817-1008 * Fax:
901-375-3430
http://www.zex.com
What Is Nitrous Oxide? Nitrous oxide is a gas composed of two
nitrogen atoms bonded to one oxygen atom. The scientific
abbreviation for one nitrous oxide molecule is N2O where N is
nitrogen, and O is oxygen. This is where the familiar phrase
'N-2-O' comes from when people talk about nitrous oxide. How
Nitrous Oxide Makes Power Nitrous oxide kits make large amounts of
horsepower by allowing an engine to burn more fuel. Burning more
fuel creates higher cylinder pressures that will push down on the
pistons with greater force. When the nitrous is injected into an
engine and the initial combustion takes place, it creates enough
heat to separate the nitrous oxide into its two components,
nitrogen and oxygen. Once separated, the additional oxygen is then
free to react with additional fuel. To run nitrous successfully and
safely, you have to introduce precise amounts of additional fuel
with precise amounts of nitrous oxide. All of the extra oxygen
provided by the nitrous oxide must have fuel with which to react or
you may damage your engine severely. When the amount of nitrous and
the amount of supplemental fuel are controlled precisely, your
engine can safely and reliably generate exceptional power
increases. Wet & Dry Nitrous Systems A fuel injected dry
manifold system uses a spray nozzle to deliver only nitrous oxide
to the intake. A wet manifold system introduces fuel and nitrous
into the intake manifold. With a dry manifold system, the
additional fuel is supplied by increasing fuel delivery from the
injectors when the nitrous system is activated. It is called a dry
manifold system because there isn't any fuel present in the intake
manifold. The ZEX™ Nitrous System is a dry system. Powerful
Features, Plus it's Easy to Use and Easy to Install The ZEX Nitrous
Oxide System automatically adjusts the amount of enrichment fuel in
relation to the nitrous bottle pressure, thereby maintaining
consistent nitrous to fuel ratios. The result is greater power and
reliability at all bottle pressures. Our solenoid is more efficient
and require far less current draw than our competitor’s kits. This
reduces the chances of burnt wires, blown fuses, etc. from
excessive solenoid current draw. Once armed, the ZEX™ Nitrous
system is engaged at wide open throttle by an electronic switch
that uses the engine's throttle position sensor (TPS) circuit.
Wiring the switch is easy-just tap the kit's white wire into the
TPS voltage
PARTS LIST (1) Nitrous Management Unit (1) Nitrous Supply Bottle,
10lb. (Supplied Empty) (1) 2-ft stainless steel braided hose, -3AN
(1) 15-ft stainless steel braided hose, -4AN (1) Nitrous spray
nozzle (1) Bulkhead fitting assembly (1) 1/16 NPT tap (2) 3-ft
length of rubber hose (3/16 SAE30R/KY) (4) Hose clamps (1) Tall
bottle bracket (1) Short bottle bracket (1) Mounting bolts and nuts
(1) Arming switch/wire harness (2) Wire T-taps (1) Barrel connector
(1) Spade connector (1) Ground ring terminal (10) Black cable ties
(2) Grommets (1) Instructions (1) Tune-up sheet
ZEX™ * 3418 Democrat Rd. * Memphis, TN Phone: 888-817-1008 * Fax:
901-375-3430
http://www.zex.com
output. Simple and reliable! It's easy to install, with all the
major components (solenoid, electronic throttle switch, and nitrous
manifold) contained in an attractive enclosure with a pre-
assembled wiring harness. It's a "plug and play" installation! Why
Our Nitrous System Is Better? What makes our dry manifold nitrous
system work so well is that the fuel control circuit references the
actual bottle pressure to determine enrichment fuel needs. The
other kits on the market use fuel regulating systems that ignore
bottle pressure entirely, thus producing a constant level of fuel
enrichment no matter how much nitrous is really going into the
engine. Ours, in contrast, is self adjusting within its operating
range. This difference in approach allows our kit to have optimum
nitrous to fuel ratios at all bottle pressures. That is how we can
give you more horsepower per pound of nitrous and less chance of
engine destroying detonation. Even our method of system engagement
is better. Most current nitrous systems use a throttle arm actuated
micro-switch. That means you have to fabricate a mounting bracket
for the switch and adjust the placement of the switch to make it
work right. Our nitrous kit utilizes a wire that you simply clip on
the throttle position sensor (TPS) output voltage wire. The TPS
voltage signal is sent to a programmable electronic switch that
engages and disengages the system at a predetermined voltage
threshold. Above the threshold determined for wide open throttle,
the system activates. Below the voltage threshold, it remains
dormant. How The ZEX Nitrous Oxide System Works The ZEX™ Nitrous
oxide injection kit begins with a supply cylinder containing
pressurized liquid nitrous oxide. This cylinder is connected by
means of a delivery hose to a normally closed electric solenoid
valve. This solenoid valve, which is attached to a manifold
assembly, is engaged and disengaged via the TPS switch. The
manifold assembly distributes the nitrous oxide to the engine's air
inlet and the kit's supplemental fuel control circuit. The nitrous
oxide that is delivered to the engine's air inlet is conveyed via a
delivery hose to an injection nozzle. The amount of nitrous oxide,
which provides the oxygen required for the horsepower increase, is
adjustable by means of a metering jet installed in the injection
nozzle itself. The nitrous oxide that is distributed to the fuel
control circuit passes through a small bleed orifice. This bleed
orifice provides a reference source of bottle pressure and a
controllable source of pressure to perform the needed function of
fuel enrichment. Fuel enrichment occurs by conveying this source of
pressure through a delivery hose to the vacuum port on the fuel
pressure regulator. This source of pressure on the rubber diaphragm
of the fuel pressure regulator causes an increase in fuel pressure.
This increase in fuel pressure performs the function of adding fuel
volume through the engine's own injectors. The amount of additional
fuel that is added can be changed by an adjustable metering jet in
the fuel control circuit. This jet accomplishes the task by
controlling the amount of pressure allowed to build in the delivery
hose to the fuel pressure regulator. The jet bleeds off excess
pressure in the fuel control circuit and vents it through a
delivery tube, back to the intake manifold plenum.
ZEX™ * 3418 Democrat Rd. * Memphis, TN Phone: 888-817-1008 * Fax:
901-375-3430
http://www.zex.com
How to Adjust Power Levels The ZEX™ Nitrous kit is designed for
multiple power levels. These levels are controlled by metering jets
installed in the nitrous nozzle and fuel jet holder. To change the
power output, all you need to do is install the appropriate set of
jets as shown in FIG.1. The correct combination of jets is listed
on the tune- up sheet on the back of this instruction manual. Quick
Start Reference Guide Work Safely: Always wear eye protection and
gloves when working with lines or hoses that contain pressurized
nitrous oxide or fuel. Never transport nitrous cylinders loose in a
trunk or the back of a pick-up truck and especially NOT within a
vehicle's interior whether the cylinder is full OR empty. Always
disconnect the GROUND side of the battery when working on any
electrical components. Nitrous Oxide won't fix problems you already
have: Before you install your nitrous system, be sure your engine
is in good mechanical condition. Intermittent wiring problems,
etc., can lead to erratic system performance and possible engine
damage. Never defeat the operation of the safety relief disc in the
nitrous cylinder's valve stem: It's required by law and is there
for your safety. Never drill, machine, weld, deform, scratch, drop,
or modify a nitrous oxide tank in ANY way whatsoever! Never
overfill nitrous cylinders: That little bit extra will put you and
others at risk of injury. More often than not, when the cylinder
warms up, the pressure goes above the limit of the safety relief
disc and you lose all the nitrous you just paid for. All the power
comes from the fuel, not the nitrous: Nitrous oxide is simply a
tool that allows you to adjust how much and how quickly the engine
burns the fuel. If the fuel isn't there, the power won't be either.
Avoid detonation at all times: Nitrous enhanced detonation is much
more damaging than detonation that occurs when naturally-aspirated
due to the increased amount of fuel available for releasing energy
and the fact that more oxygen is present. If, when your system is
activated, something doesn't feel or sound right, BACK OFF: If you
hear any detonation or feel anything unusual, get off the throttle.
It's a lot easier to check everything over than it is to just try
to drive through it and damage expensive parts. Don't
Fig. 1
ZEX™ * 3418 Democrat Rd. * Memphis, TN Phone: 888-817-1008 * Fax:
901-375-3430
http://www.zex.com
activate or have the system activated when you hit the stock rev
limiter. The stock rev limiter is a fuel cutoff. If you cut fuel
while you're injecting nitrous, you're instantly very lean. This
momentary lean condition has the potential of causing engine
damage. Engine Modifications: The ZEX™ Nitrous System, out of the
box, is designed to work as a bolt-on kit for stock or mildly
modified vehicles. Mildly modified vehicles would include header
upgrades, exhaust upgrades, air filter kits, etc. If major engine
modifications have been performed, larger injectors and a fuel pump
upgrade will be required for safe nitrous system operation. Major
engine modifications would include turbochargers, superchargers,
aftermarket cylinder heads, head porting, camshafts, intake
manifolds, etc. Failure to upgrade the fuel system when using
nitrous in these highly modified applications may cause serious
lean conditions that can result in severe engine damage. Spark
Plugs & Nitrous Performance: Quite often, a factory type
wide-gap projected nose plug will produce a detonation condition
after a few seconds of nitrous use. The detonation is not due to
the heat range, it occurs because the ground strap of the spark
plug becomes a glow plug instead of a spark plug. The ground strap
is too long to dissipate the extra heat produced by a nitrous
accelerated burn. The correct solution is to replace the plugs with
units that have shorter ground straps. By doing this, you will
shorten the heat path from the ground strap to the plug base. ZEX™
Hyperformance™ spark plugs are recommended for many applications.
Reading Plugs & Tuning ZEX Nitrous Kit: If you've installed
larger injectors or have otherwise increased the capacity of your
fuel system, you need to read the following. Because the real limit
of how much power you make with the ZEX™ Nitrous Kit is your car's
fuel system, you need to tune up to that limit. Start with the
lowest power level nitrous jet and corresponding fuel metering jet.
Make a full throttle pass at the drag strip and read the plugs. Not
enough nitrous/too much fuel results in a sooty, black plug
coloration. This coloration means that the fuel mixture is too
rich. Too much nitrous will exhibit high heat in the form of a
bluish or rainbow-like coloring on the plug's metal surfaces. This
means you're engine is about to, or is, detonating. If this is
observed, ensure the proper spark plugs are installed, reduce
nitrous/increase fuel delivery, and ensure the proper grade of fuel
is being used. When you check the spark plugs, check EVERY plug.
Don't just spot check the easiest plug you can access. Due to the
wide possibility of air/fuel mixture variations, you need to check
every single plug for signs of detonation or other problems. If
your plugs indicate too much fuel, trim the fuel delivery down by
installing a larger metering jet. If you are too lean/not enough
fuel, you need to install a smaller metering jet to increase fuel
delivery. Clear Nitrous Lines After Use: Close bottle valve. Use
purge kit to relieve line pressure or open line fitting to let
nitrous bleed off.
ZEX™ * 3418 Democrat Rd. * Memphis, TN Phone: 888-817-1008 * Fax:
901-375-3430
http://www.zex.com
Installation Instructions Step 1: Decide Where to Put Everything
Before you drill a hole in your car, make sure you know where
you're going to install the various components of this kit. You'll
have to discover the best positions for each component by trial and
error. First, the nitrous line that attaches to the engine air
intake is about 2-feet long. That means where you choose to install
the nitrous nozzle decides, within a 2-foot radius, where you have
to mount the Nitrous Management Unit. Also, you need to connect the
vacuum/pressure circuit for the fuel pressure regulator to the
Nitrous Management Unit, so be aware of the distance between these
components. You'll also have to decide where to install the arming
switch and nitrous bottle. The arming switch should be installed in
a positioned convenient to the driver, but not in an area that
increases the chance of unintentionally arming the system. You'll
have to run a wire through the firewall to the Nitrous Management
Unit. Do it just like you would run a lead for your stereo system.
In fact, if you have one installed, you can probably run the arming
lead through the same grommet. If not, try to use a wire loom hole
that is grommeted. To help decide where you'll mount the nitrous
supply bottle, check the following section for technical
restrictions on bottle mounting locations and positions. Step 2:
Mount Nitrous Supply Bottle Mount the nitrous supply bottle so that
it is separated from the passenger cabin. Fastback style cars that
do not have separate trunk compartments have to be equipped with a
safety blowdown tube. Route the tube from the safety pressure
relief cap to the exterior of the car, preferably under the car.
Doing so will prevent your car from filling with a cloud of nitrous
oxide should the safety pressure relief cap rupture. Index the
pickup tube with bottle position. (Refer to fig's A, B, and C).
ZEX™ nitrous bottles are designed with the bottom of the siphon
tube at the bottom of the bottle towards the outlet. Always mount
the bottle so that as your car accelerates, the liquid flows toward
the pickup tube. Step 3: Mount Nitrous Delivery Line Under The Car
When routing the nitrous delivery line under the car, try to use
the subframe as a conduit. This protects the line and eliminates
the need to use clamps. The supplied cable ties work if you can run
the line higher in the under-body so that it's safe from road level
obstacles such as speed bumps. For the pro-race look, you can use
steel loom clamps with rubber sheathing to fasten the line to the
body.
Fig. A
Fig. B
Fig. C
ZEX™ * 3418 Democrat Rd. * Memphis, TN Phone: 888-817-1008 * Fax:
901-375-3430
http://www.zex.com
Step 4: Mount Nitrous Management Unit Keeping in mind the length
restrictions of the nitrous nozzle feed line and hose connections,
mount the Nitrous Management Unit in a suitable location. Use the
four screw holes provided for this purpose. It's a pretty rugged
piece of equipment that is built to withstand underhood
temperatures as well as exposure to weather. Step 5: Install
Nitrous Nozzle Optimum nozzle placement is 6" to 18" from the
throttle body. After you have determined where to mount the nitrous
nozzle (Fig. F) in the intake, make sure this location won't
interfere with other components. If your engine uses a mass air
flow sensor, mount the nozzle after the sensor, but before the
throttle body. After you've found the spot, mark it and remove the
rubber air inlet duct from your engine. Drill a 7/16-inch (.4375)
mounting hole and install the bulk head fitting. Be sure to remove
any drill shavings since they can severely damage your engine.
Install the nitrous nozzle so that the spray is in the direction of
airflow.
We've enclosed a tap (Fig. F) should you need to mount the nozzle
in a metal duct. Just drill a 1/4 (.250)-inch hole where you want
to mount the nozzle, tap the hole and install the nozzle. Once the
nozzle is installed, place the appropriate tuning jet in the nozzle
and tighten the 2-foot long, -3AN hose over the nozzle end (Fig.G).
Step 6: Install Regulator & Intake Hoses Measure & cut to
length the two hoses that lead from the Nitrous Management Unit's
regulator and intake hose barbs. The regulator hose barb from
the
Nitrous Management Unit gets connected to the vacuum fitting on the
engine's fuel pressure regulator with one of the lengths of hose.
The intake hose barb from the Nitrous Management Unit gets
connected to an unused vacuum fitting coming off of the intake
manifold plenum with the other length of hose. Install the fuel
tuning jet in the holder as seen in Fig. G and tighten the hose
barb / tube nut assembly over the top of the jet. Step 7: Wire It
Once you have mounted the components, you are ready to wire the
nitrous system. From the Nitrous Management Unit, find a suitable
ground for the black wire and
Fuel Jet Holder
ZEX™ * 3418 Democrat Rd. * Memphis, TN Phone: 888-817-1008 * Fax:
901-375-3430
http://www.zex.com
connect to it with the included crimp-on ground ring. Run the red
wire through the firewall of the vehicle into the interior, behind
the dashboard. Ensure that the red wire passes through a grommeted
hole and not a bare metal hole. The wire's insulation may be rubbed
off if put through a non-grommeted hole. Run the white wire from
the Nitrous Management Unit to the output voltage lead from the
throttle position sensor. After those connections are completed,
you need to install the arming switch/wire harness assembly. Find a
suitable place in the interior of the vehicle for the arming switch
and drill a 1/2 inch (.500) hole. Mount the switch and switch cover
through this hole. Take the lead that the fuse assembly is attached
to and find a suitable 12 volt accessory source of power under the
dash. Use the T-tap electrical connector to splice into the 12 volt
accessory wire and plug in the wire harness lead. Take the other
lead from the arming switch and connect it to the red wire from the
Nitrous Management Unit. As a reference for wire locations, use
Fig. D. STEP 8: Program Activation Switch & Check Vacuum and
Pressure Lines Now that you have completed the installation and
wiring of your nitrous kit, one of the final steps is to program
the Activation Switch and check the vacuum and pressure lines. To
program the Activation Switch, turn the vehicle's ignition on, but
do not start the engine. Turn the nitrous arming switch to the "ON"
position. Go to the Nitrous Management Unit (NMU) and locate the
push-button switch. Depress, then release, the push-button switch.
Observe the NMU's Operation Light. At this point, it should be RED.
This RED light informs you that the NMU's Activation Switch is in
learn mode. Return to the driver's seat and depress the accelerator
pedal to the floor, holding it there for ten seconds. Release the
accelerator pedal and go back to the NMU and observe the Operation
Light. At this point, the light should be flashing continuously
from RED to GREEN to OFF. This is the NMU's way of telling you that
it has successfully learned the voltage curve of your engine's
throttle position sensor. Go back to the driver's compartment and
turn off the system's arming switch, then turn it back on. Go back
to the NMU and observe the Operation Light. It should be solid
GREEN at this point. This informs you that the system is armed and
ready to activate at wide-open throttle. Return to the driver’s
seat and depress and release the accelerator pedal several times.
You should hear the solenoid click each time you reach wide-open
throttle. At this point, your Activation Switch is fully programmed
and ready for use. If you ever transfer your nitrous system to
another vehicle, perform this same procedure on the new vehicle to
"relearn" the NMU's Activation Switch. To ensure that the system is
ready to be used, a final vacuum and pressure check of the system's
hoses and lines must be done. With the engine running, check your
"intake" and "regulator" hoses for any vacuum leaks. Generally a
vacuum leak will cause the engine to run rough. Assuming the vacuum
lines check out, open the nitrous bottle valve. Listen carefully to
your engine as the valve is opened. You should not hear a
difference in idle speed or engine sound. If you notice either of
these changes, call the ZEX™ product support line. If there is no
change in idle speed or engine sound, shut the engine off at this
time and inspect the nitrous pressure lines and fittings for leaks.
Leaks in the nitrous supply line will be obvious because they will
be covered with frost. STEP 9: Check Fuel Quality & Ignition
Timing The last thing to do before enjoying your new nitrous system
is to ensure that premium fuel (92 R/M Octane or better) is in the
fuel tank and that your ignition timing is set correctly. All
ZEX™ * 3418 Democrat Rd. * Memphis, TN Phone: 888-817-1008 * Fax:
901-375-3430
http://www.zex.com
recommended ignition timing retard amounts, on the Tune-Up Sheet,
are calculated off of the base, stock ignition setting. It is
important to set this with a timing gun before you use your nitrous
system for the first time. Do not assume that it is set properly.
If the ignition timing is not set correctly, severe engine damage
may occur. Need Help? If there are any questions or problems during
installation of your new ZEX™ Nitrous Injection System, please do
not hesitate to contact the toll free ZEXTEK™ line at
1-888-817-1008.
ZEX™ NITROUS KIT #82011 TUNE -UP SHEET
55HP 65HP 75HP NITROUS JET 32 35 38 FUEL JET 36 34 32 IGNITION
RETARD 0° 2° 4° Premium quality fuel, 92 R/M octane or better, is
required at all times for safe operation of your ZEX™ Nitrous
System.
Part # ZEX109 Revised 1/22/04